Let's Build A 1 Ton Crew Cab 4x4

[NastyBuzzard]

Originally Posted by deejaaa1

love those D-Max rims.

Originally Posted by Dieselwrencher

Nice work and you guys are making some good progress with your business. Are you marketing the rear disc mounting brackets or are they available some where else?

You actually like those bullet holes? I am trying to find stock-os or something to replace them currently. I mean, I don't mind them but im not a huge fan. They definitely remind me of my square

Yes, we plan to market them. We have a page on facebook showing them off and what not. Should be available in the coming weeks for purchase. Just need to create a website and all that jazz. Working hard on finishing the plasma table.

[deejaaa1]

yeah, those bullet holes would look good on my 93.

[NastyBuzzard]

Quick solution to the oil cooler issue. Just picked up these 1/2 NPT fittings from lowes to make a short bypass for now until I get it all figured out.



At least that was the plan, then I went to the junkyard on Saturday and found a complete 6.2 radiator setup.



Now I just need to figure out lines from block to these long aluminum lines pictured below the radiator.

Started cleaning up a tad... Started admiring the truck, then decided I wanted to put the bed on.















Wheel is back in the center!!!





So as of right now it is 1-1/4" higher up front. It is also still missing a lot of weight up front and the 4" lift springs are new and haven't settled. I may go back and add the overload spring to the rear which will bump it up about 3/4" of an inch.. Otherwise I will be swapping the front 4" lift springs for 2.5" lift springs.

[MTCK]

Well heck yeah! If you put the bed on you have to do the front fenders! Looking real good. How far back did you move the rear axle? I'm about to embark on a shackle flip myself. Remember when you are measuring height that the front wheel opening is larger, so measure to the body line. I learned that when I was complaining to tuff country that my front springs sat too high.

[NastyBuzzard]

Yep! I had to bolt on one fender just to see, ya know! Even if its coming right back off.

I moved the axle back 1-1/2" with the EZ Inch block.

Yeah, my measurements are done off the body line.

Fun part was putting the bed on by myself, at least its a short bed now. I need this 6.5 to run before I fall in love with the Duramax.

[NastyBuzzard]

Doing some test fitting.

(I realize I have it backwards) EP158 screwed right into the TBI lines! Which makes that a lot easier.



All this is really tight but it fits. Curious if this is really the way to go.



Super tight fit between banks turbo and the alternator. Is this ok?



Also, which valve to use? I figured use the banks one, but how to plug the hole in the valve cover? Or does it need to be routed elsewhere?

[NastyBuzzard]

So I have been trying to get this thing together enough to fire it up. I want to make sure this engine is ok and doesn't sling apart first time I fire it up.

My buddy came over Saturday and started rewiring and repining the 83 6.2 fuse block, engine wiring and cab wiring for me to work with the 88 steering column and what not. He does amazing work I am so glad to have his help that is for sure.



I have ran into some slight hangups though.

First one is I can't get a bolt in this spot for manifold, the frame is in the way.



Had to modify the banks oil return.





Another thing is where to find a new bushing for the throttle cable. Also I need the retainer clip to hold throttle cable on.



Also, since I am running the 6.2 IP stuff on the 6.5 will I have to do something funky for throttle cable linkage? I have the 6.2 linkage, I removed the cruise control piece from it and still have to put the other piece back on the IP.

I have decided to use the 6.5 stock fuel filter setup for now.

I bought a 6.2 OPS... Where does it mount? I tried taking out the plug in the back of the block but it was same size thread as the 6.5 OPS. Or should I just use the 6.5 OPS and wire in the plug for it? Is there some type of 90deg adapter I am missing? I remember those on the old 350s.



Also working on hooking up steering components.

Does this look right? Angle wise I mean.

[wildwilly4x4]

Way too much angle on that drag link....need it flat as possible or its gonna be very screwy to drive. They make a steering block that fits on the axle to raise the arm up higher.

IIRC on the exhaust manifold bolt on mine, I was able to get just enough clearance by jacking up on the motor and pulling that sides motor mount bolt.

I don't remember having to modify my throttle linkage stuff for the 6.5 manifold, but I did have to notch the 6.5 engine cover for the cable.

[NastyBuzzard]

That's what I thought. I was like wait a minute... I used the drop steering link that mounts to the gear box. I think its because currently I have around 5.5" of lift instead of 4". Once I swap down to 2" lift springs I should have around 3.5" lift up front instead. Otherwise I will definitely have to find one of those blocks.

Yeah I will try that, didn't think of that. Didn't want to have to notch frame for it.

Good to know about the cover.

Any clues on the adapter for the oil pressure sensor/switch? Or the throttle cable?

[NastyBuzzard]

Working on engine wiring. Thanks to my buddy it is turning out to look quite nice. Had to bring one piece into work this morning for some soldering because of damaged ends.



Since I elected to use the 6.5 fuel filter setup for now I had to clearance the bracket that mounts to it for the 6.2 vacuum pump.



Any way to clean up these glow plug wires? Also I am using a 6.5 dipstick & tube but it doesn't seem to jive well with the 6.2 manifolds. Do I need a 6.2 dipstick?



I also need a 45deg or 90deg adapter for the oil pressure switch 1/4 npt male to 1/8 npt female. Having a tough time trying to find one of those.

Also, I purchased a 88+ throttle cable b/c the bushing in mine was shot. It was a GM cable off ebay, I heard you could use them with slight modification. Ending up not fitting in my bracket so basically paid $30 for the line just to take the bushing out of it and put into my 80s 6.2 throttle cable. Also, is this really called the idle air control valve?



Few more parts to order this week. I need hydroboost lines, and the older style temp switches/sensor.

[NewType72]

Absolutely incredible detail work in this one. Really love the build and makes me dream of the 4x4 short crew that is mocked up on the longest back burner storage room we have

[wildwilly4x4]

That's a fast idle solenoid.

[NastyBuzzard]

Unfortunately, it isn't my best work but I am trying. I really wish I had the extra time and funds to use an entirely new engine but I have got to see if this one is going to run or sling apart first. Still a long ways to go for sure but I love it!

[daddyjeep]

Originally Posted by NastyBuzzard

Unfortunately, it isn't my best work but I am trying.

You are doing just fine. You are not building a show truck here. Just like my build, it will be a nice truck when you are done that can still be used as a truck.

[NastyBuzzard]

Exactly, this is very much so a purpose built truck.

Now of course I would like for it to look good and be reliable so I am working towards that.

[NastyBuzzard]

If anyone is interested in the 14BFF disc brake adapter brackets I designed please let me know or contact me. I have some extras.

[NastyBuzzard]

WTH Photobucket. What a scummy move!

[daddyjeep]

Originally Posted by NastyBuzzard

WTH Photobucket. What a scummy move!

Agreed....it looks like we now have to pay $99 per year to be allowed to share our pics. This is going to affect millions or people and every forum on the planet.

[deejaaa1]

on GMT400, the admin was able to somehow get the photos to link up again. don't know any details but i know there's a way. if someone will notify this admin, i can search and get them in touch.
looks like PB is trying to hold our pics hostage for money. we need special ops to go in.

[NastyBuzzard]

Yeah it's ridiculous! I need to find another image hosting site. Even though I haven't touched truck much. Been real busy getting our little side plasma cut business going but I will return to it very soon!

[NastyBuzzard]

I am torn with what to do with this thread... Photobucket really screwed us with that crap.

Should I continue on or what?

Here are some updates. 4WD conversion is damn near complete on all of our cutbros parts finally. I am ready to get back working towards getting this thing on the road!

EDIT: NO CLUE WHY THEY ARE SO BIG FOLKS!

[MTCK]

I'd just pick up where you are at and continue.

[Wide Open]

Yeah I'd say just continue on.

[NastyBuzzard]

Well alrighty then. Just have to figure out how to get the pictures not to be so large. I am trying hosting on Imgur b/c its the only other reliable pic hosting site I know of.

[daddyjeep]

I agree, keep it going. I have been using Google Drive with good luck on Wranglerforum, but on here it makes images huge just like yours.